Automatic sensing of safe-operation sensor apparatus and method

ABSTRACT

A movable barrier operator having a microprocessor ( 10 ) or other programmable platform will automatically work in a safe and appropriate manner both with and without safe-operation sensors ( 13 ). Once a safe-operation sensor is detected, the operator will thereafter function in a fashion that requires the continued presence of such sensor. In one embodiment, the operator state can be purposely reset to the initial operating state.

TECHNICAL FIELD

[0001] This invention relates generally to safe-operation sensing andmore particularly to movable barrier operators.

BACKGROUND

[0002] Movable barrier operators are well known in the art. Suchoperators generally serve to selectively move a movable barrier (such asa segmented or one-piece garage door, swinging gate, sliding gate,rolling shutter, and so forth) between an opened and a closed positionusing one or more motors. It is also known to use safe-operation sensorswith such operators to aid in ensuring that the movable barrier can beso moved without undue risk to persons or property in the immediatevicinity. Typically, such sensors are designed to detect an obstacle inthe path of the moving barrier (particularly when the moving barriermoves to a closed position) through use of light, sound (includingultrasonic sound), radio-frequency, and/or contact sensing mechanisms.Upon sensing an obstacle, the sensor provides a corresponding signal,which signal can be used by the movable barrier operator accordingly toaid in avoiding potentially harmful contact between the movable barrierand the detected obstacle.

[0003] Typically, movable barrier operators that are designed for usewith a safe-operation sensor will not function without thesafe-operation sensor being coupled to the operator. This arrangement isintended to prevent obstacle collisions from occurring should theoperator be installed or later operated for whatever reason without thesafe-operation sensor being coupled thereto. Such a design, however,limits the range of application for the operator itself. While somejurisdictions require the concurrent use of a safe-operation sensor,other jurisdictions do not. Further, many jurisdictions that requiresafe-operation sensors do not require such sensors for all potentialapplications (for example, such sensors may be required in a residentialcontext but not in an industrial context) and/or some users injurisdictions that do not require such sensors may neverthelessthemselves wish to use such safeguards. By designing an operator tospecifically require concurrent coupling to a safe-operation sensor,economies of scale are lost because such an operator cannot address someof the above significant market needs.

[0004] In likely recognition of these circumstances, there are at leastsome movable barrier operators that can function with, or without, asafe-operation sensor. As shipped, such operators are typicallyprogrammed as non-sensor operators, meaning that the operator may beinitially installed and operated without coupling a safe-operationsensor thereto. In the alternative, at the time of installation or atany time thereafter, trained personnel can connect a safe-operationsensor to the operator (typically by connecting appropriatesignal-carrying conductors either directly to a motherboard (using, forexample, terminal posts provided for this purpose) or by coupling theconductors to an intermediary board (or card) that is inserted into acorresponding socket or base on the motherboard). Once so connected, theinstaller than usually configures a dual inline package (DIP) switch asprovided on the operator to initiate a learning mode and thereby informthe operator of the existence of the safe-operation sensor. The operatorwill then function thereafter in tandem with the sensor.

[0005] Unfortunately, installers often forget or otherwise neglect toinitiate or complete the learning step described above. As a result,even though the safe-operation sensor is coupled to the operator (andmay even be drawing working current therefrom), the operator in fact isunaware of the sensor and is not paying attention to any obstacles thesensor detects. This improper installation can of course lead to unsafeand even dangerous circumstances. Therefore, such prior art approachesused to address the need for a dual-mode movable barrier operator can infact raise additional problems and concerns.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The above needs are at least partially met through provision ofthe automatic sensing of safe-operation sensor apparatus and methoddescribed in the following detailed description, particularly whenstudied in conjunction with the drawings, wherein:

[0007]FIG. 1 comprises a block diagram schematic as configured inaccordance with an embodiment of the invention;

[0008]FIG. 2 comprises a generalized flow diagram as configured inaccordance with an embodiment of the invention;

[0009]FIG. 3 comprises a more detailed flow diagram as configured inaccordance with an embodiment of the invention;

[0010]FIG. 4 comprises a detailed flow diagram as configured inaccordance with an embodiment of the invention;

[0011]FIG. 5 comprises a block diagram as configured in accordance withyet another embodiment of the invention;

[0012]FIG. 6 comprises a detailed flow diagram as configured inaccordance with yet another embodiment of the invention; and

[0013]FIG. 7 comprises a detailed flow diagram as configured inaccordance with yet another embodiment of the invention.

[0014] Skilled artisans will appreciate that elements in the figures areillustrated for simplicity and clarity and have not necessarily beendrawn to scale. For example, the dimensions of some of the elements inthe figures may be exaggerated relative to other elements to help toimprove understanding of various embodiments of the present invention.Also, common but well-understood elements that are useful or necessaryin a commercially feasible embodiment are typically not depicted inorder to facilitate a less obstructed view of these various embodimentsof the present invention.

DETAILED DESCRIPTION

[0015] Generally speaking, pursuant to these various embodiments, duringat least one normal operating mode of a movable barrier operator, theoperator will detect the presence of at least one safe-operation sensor(automatically and without user initiation) and, upon detecting thepresence of such a sensor, will thereafter alter at least one normaloperating mode of the movable barrier operator whenever thesafe-operation sensor is thereafter not detectable. So configured, theoperator can serve both with and without a safe-operation sensor withoutrequiring a specific user-initiated learning mode. Furthermore, once theoperator has been used with a safe-operation sensor, the operator willthereafter alter its normal operation should the sensor become availablefor whatever reason (such as by removal of the sensor, damage to thesensor, and/or mis-calibration and/or misalignment of the sensor forwhatever reason).

[0016] In one embodiment, a user-initiated learning mode can be used toreconfigure the operator to work in an ordinary fashion without thesensor once the operator has automatically detected the sensor asdescribed above. So configured, the operator can later be successfullyused without a sensor should such an operating mode be explicitlydesired by a user.

[0017] In another embodiment, multiple sensors can be used by theoperator, and the reaction of the operator to the absence of one or moreof these sensors can be predetermined as appropriate to the givenapplication.

[0018] In the specific embodiments presented below, the movable barriercomprises a garage door and the safe-operation sensor(s) comprises aninfrared light-based obstacle sensor, both as well understood in theart. These specific embodiments serve an illustrative purpose only asthe inventive concepts are readily applicable to other kinds of movablebarriers and/or safe-operation sensors.

[0019] Referring now to FIG. 1, a typical movable barrier operator willhave a microprocessor 10 (or microcontroller or other programmableplatform or, in some instances, a hard-wired logic platform) thatcouples through a motor control 11 interface to a motor 12 that is usedto effect powered movement of a movable barrier (typically betweenclosed and opened positions and vice versa). In this embodiment, themicroprocessor 10 also couples to a safe operation sensor 13 (againcomprising, in this embodiment, an infrared light-based obstacle sensoras well understood in the art) through a circuit comprising, in apreferred embodiment, an operational amplifier 14 (such as, for example,an LM324) having its positive input coupled to a voltage divider thatincludes two resistors 16 and 17 and having its negative input coupledto a grounded resistor 15 that itself couples to the sensor 13. In apreferred embodiment, the output of the operational amplifier 14 couplesto an appropriate interrupt pin of the microprocessor 10 such thatintermittent pulses as output by the sensor are readily detectable bythe microprocessor 10.

[0020] So configured, coupling of the safe-operation sensor 13 to themicroprocessor 10 can be readily detected in support of thefunctionality described further below. In addition, if desired, a signalunit 18 can be provided to source a user-discernable signal to indicateeither that the safe operation sensor 13 has been coupled, is coupled,and/or is no longer coupled as desired (such a signal can be any mannerof audible, visual, or other user discernable indicia as may beappropriate in a given application, or any combination thereof). Also,again if desired, a switch 19 (such as a DIP switch as well known in theart) can optionally be provided for purposes that are described below inmore detail.

[0021] Pursuant to these embodiments, the microprocessor 10 (or otherprogrammable platform as is otherwise provided) can be programmed ordesigned to operate in an initial first mode of operation, which firstmode of operation includes detecting connection of the safe-operationsensor 13. In response to detecting such connection, the microprocessor10 thereafter operates in a subsequent second mode of operationregardless of whether the safe-operation sensor 13 remains connected tothe microprocessor 10. For example, in the first mode of operation, themovable barrier can be moved from an opened to a closed position evenwhen a safe-operation sensor is not attached. In the second mode ofoperation, however, when the safe-operation sensor is not attached andworking properly, the movable barrier might not be readily movable fromthe open position to the closed position.

[0022] Referring now to FIG. 2, and considering such detectionfunctionality 20 from an overall viewpoint, the movable barrier operatordetects 21 whether a safe-operation sensor has been attached thereto. Ifnot, the detection functionality concludes 23 and the operator continuesin an ordinary fashion (such detection can occur as frequently orinfrequently as is appropriate or desired in a given set of operatingconditions). When a sensor is detected 21, however, the operating modeof the operator is altered 22. In particular, the operating mode isaltered such that the operator will now require the presence of thesafe-operation sensor. This functionality occurs automatically andwithout specific user initiated actions. The operator becomes asensor-equipped operator simply by attaching the sensor to the operatorand operating the operator in an ordinary and regular fashion. The userneed not specifically initiate or enable a learning mode as is typicallyrequired in the prior art.

[0023] Pursuant to one embodiment, and referring now to FIG. 3, when thesensor detection 21 described above detects the presence of a sensor, acount S can be incremented 31. This count S is then compared 32 againsta threshold value X (such as, for example, 5). The process can thencontinue to monitor for subsequent indicia of the presence of thesensor. Through such a process, false positives that inaccuratelyindicate the presence of a sensor can be largely prevented fromtriggering the new behavior of the operator. Once enough confirmingevents have occurred (for example, when the threshold is set to “5” and5 positive detections of the sensor occur) a sensor flag can be set 33(for example, by writing to a corresponding field in an EEPROM memorythat is internal to or otherwise operably coupled to the microprocessor)and the process then continues as described earlier.

[0024] If desired, a time window can be built into this process suchthat a sufficient number of such confirming detections must occur withina specific predetermined period of time. Otherwise, the count S can bereset to zero.

[0025] Such an approach allows for operation as set forth in FIG. 4.During operation 40, the microprocessor determines 41 whether the sensorflag described above has been set. If not, no safe-operation sensor hasbeen previously detected and the operator engages in its normaloperating mode 42. When, however, the sensor flag has been previouslyset, the operator then determines 43 whether the safe-operation sensorremains so connected. When true, normal operation again prevails 42.When the sensor is not, however, still attached (and operating in aproper manner), the operator alters 44 its operating mode.

[0026] The precise nature of the alteration can vary with the specificapplication. For example, the closing mode can be altered, the openingmode, a stopped-waiting-for-action-to-be-initiated mode of operation, orall of these (altering both the opening and closing process isparticularly appropriate when using these concepts with a sliding gatestyle of movable barrier operator). The alteration itself can includepreventing full or partial closing or opening of the movable barrierand/or movement of the movable barrier in a direction opposite thatwhich has been instructed by a user.

[0027] In the embodiments described, a single safe-operation sensor hasbeen attached to the operator. These concepts are readily extendable touse with multiple sensors, however. For example, as shown in FIG. 5, twosafe-operation sensors 51 and 52 can be coupled to a single operatormicroprocessor 10 as is already understood in the art (for example, twoinfrared light sensors may be used with a single operator to monitor twodifferent areas of the opening for potential obstacles).

[0028] When using multiple sensors the above-described embodiments arereadily modifiable to accommodate such a configuration. For example,with reference to FIG. 6, during ordinary initial operation, theoperator can first detect 61 for presence of a first sensor and thendetect 65 for presence of a second sensor. When the first sensor isdetected 61, a count S1 as corresponds to the first sensor can beincremented 62 and compared 63 against a threshold value to alloweventual setting 64 of a flag for the first sensor (much as describedabove). Similarly, when the second sensor is detected 65, a count S2 ascorresponds to the second sensor can be incremented 66 and compared 67against a threshold value to allow eventual setting 68 of a flag for thesecond sensor. (The threshold used to test for a likely assured presenceof the first and second sensor can be the same for both sensors ordifferent as appropriate to the given situation.) So configured, theoperator can detect the presence of either or both sensors (it should bewell understood that yet additional sensors could be similarlyaccommodated if desired).

[0029] Detection of multiple sensors can be used in various ways asdesired. For example:

[0030] (1) Once a given sensor has been connected, the operator canrequire continued presence of that particular sensor (or at least thecoupling of a sensor to that particular sensor interface and input);

[0031] (2) Once any sensor has been connected, the operator can requirecontinued presence of at least one sensor (for example, if a firstsensor is coupled, and then a second sensor, and then the first sensoris uncoupled, the operator could continue to operate in an ordinaryfashion because the second sensor is still connected); or

[0032] (3) Once a first sensor has been connected, the operator canrequire the presence of multiple sensors even though additional sensorshave not yet been connected.

[0033] Other permutations and combinations are of course possible.

[0034] Pursuant to the above embodiments, a movable barrier operator cansuccessfully function as a non-sensor-based operator provided no sensorsare coupled to the operator. Once a sensor is coupled and used, however,the operator becomes a sensor-based operator and will require continuedpresence of a properly functioning sensor to ensure ordinary operation.This result occurs automatically and without the need for any specificuser-initiated learning mode. It is possible, however, that a user maywish to disconnect a sensor from an operator and have the operator againfunction as a non-sensor-based operator. To accommodate such needs, ifdesired, a switch (such as switch 19 as described in FIG. 1) or otherappropriate user interface can be provided to initiate what effectivelyamounts to an unlearn mode of operation. For example, with reference toFIG. 7, upon detecting 71 the appropriate setting of such a switch, theoperator can clear 72 the sensor flag indicia (or flags where multiplesensors are monitored) and conclude 73, thereby effectively returningthe operator to its pre-sensor state of functionality. So configured,the operator will now function in an initialized state and will notrequire the presence of a sensor to effect ordinary operation.

[0035] Pursuant to these various embodiments, a single movable barrieroperator can be used in a variety of user settings without need forspecial user training and/or actions. Instead, the operator willautomatically serve both with and without safe-operation sensors in asafe and appropriate manner.

[0036] Those skilled in the art will recognize that a wide variety ofmodifications, alterations, and combinations can be made with respect tothe above described embodiments without departing from the spirit andscope of the invention, and that such modifications, alterations, andcombinations are to be viewed as being within the ambit of the inventiveconcept.

We claim:
 1. A method for use with a movable barrier operator,comprising: during at least one normal operating mode of the movablebarrier operator: automatically detecting at least one safe-operationsensor; upon detecting the at least one safe-operation sensor,thereafter altering at least one normal operating mode of the movablebarrier operator whenever the at least one safe-operation sensor is notdetected.
 2. The method of claim 1 wherein the at least one normaloperating mode of the movable barrier operator during which the at leastone safe-operation sensor is automatically detected comprises at leastone of an opening mode of operation, astopped-waiting-for-action-to-be-initiated mode of operation, and aclosing mode of operation.
 3. The method of claim 1 wherein altering atleast one normal operating mode of the movable barrier operator includesaltering one of a closing mode of operation and an opening mode ofoperation of the movable barrier.
 4. The method of claim 3 wherein:altering a closing mode of operation of the movable barrier includespreventing a movable barrier from fully closing during a closing mode ofoperation; and altering an opening mode of operation of the movablebarrier includes preventing a movable barrier from fully opening duringan opening mode of operation.
 5. The method of claim 3 wherein: alteringa closing mode of operation of the movable barrier includes at leaststopping movement of the movable barrier towards a closed position;altering an opening mode of operation of the movable barrier includes atleast stopping movement of the movable barrier towards an openedposition.
 6. The method of claim 5 wherein: altering a closing mode ofoperation of the movable barrier further includes reversing movement ofthe movable barrier away from the closed position; altering an openingmode of operation of the movable barrier further includes reversingmovement of the movable barrier away from the open position.
 7. Themethod of claim 1 wherein automatically detecting at least onesafe-operation sensor includes automatically detecting an operableobstacle detection sensor.
 8. The method of claim 7 whereinautomatically detecting an operable obstacle detection sensor includesautomatically detecting at least one of a light-based obstacle detectionsensor, a sound-based obstacle detection sensor, a radio frequency-basedobstacle detection sensor, and a contact-based obstacle detectionsensor.
 9. The method of claim 7 wherein automatically detecting anoperable obstacle detection sensor includes automatically detectingeither of at least two operable obstacle detection sensors.
 10. Themethod of claim 9 wherein automatically detecting either of at least twooperable obstacle detection sensors includes automatically detecting atleast two of at least two operable obstacle detection sensors.
 11. Themethod of claim 10 wherein altering at least one normal operating modeof the movable barrier operator whenever the at least one safe-operationsensor is not detected includes altering at least one normal operatingmode of the movable barrier operator whenever at least two of the atleast two operable obstacle detection sensors is not detected.
 12. Themethod of claim 10 wherein altering at least one normal operating modeof the movable barrier operator whenever the at least one safe-operationsensor is not detected includes altering at least one normal operatingmode of the movable barrier operator whenever any of the at least two ofthe at least two operable obstacle detection sensors is not detected.13. A method for use with a movable barrier operator, comprising:automatically detecting at least one safe-operation sensor;automatically storing at least one indicia that corresponds to the atleast one safe-operation sensor; automatically detecting absence of theat least one safe-operation sensor; altering at least one normaloperating mode of the movable barrier operator whenever the at least onesafe-operation sensor is not detected.
 14. The method of claim 13wherein automatically detecting at least one safe-operation sensorincludes automatically detecting an obstacle detection sensor.
 15. Themethod of claim 14 wherein automatically detecting an obstacle detectionsensor includes automatically detecting at least one of a light-basedobstacle detection sensor, a sound-based obstacle detection sensor, aradio frequency-based obstacle detection sensor, and a contact-basedobstacle detection sensor.
 16. The method of claim 15 whereinautomatically detecting an obstacle detection sensor includesautomatically detecting either of at least two obstacle detectionsensors.
 17. The method of claim 13 wherein automatically storing atleast one indicia includes automatically storing the at least oneindicia in non-volatile memory
 18. The method of claim 13 and furthercomprising providing a user-discernable signal when altering the atleast one normal operating mode.
 19. The method of claim 13 whereinaltering the at least one normal operating mode includes prematurelyconcluding the at least one normal operating mode.
 20. The method ofclaim 13 wherein altering the at least one normal operating modeincludes not performing at least one portion of the at least one normaloperating mode.
 21. The method of claim 13 wherein altering the at leastone normal operating mode includes performing at least one alternativeaction.
 22. A method for use with a movable barrier operator,comprising: during at least one normal mode of operation and prior todetecting at least one safe-operation sensor: operating in an ordinaryfashion to selectively move a movable barrier without the at least onesafe-operation sensor; monitoring for availability of at least onesafe-operation sensor; automatically detecting at least onesafe-operation sensor; automatically storing at least one indicia thatcorresponds to the at least one safe-operation sensor; and during atleast one normal mode of operation and subsequent to storing the atleast one indicia: operating in an ordinary fashion to selectively movethe movable barrier as a function, at least in part, of the at least onesafe-operation sensor; automatically detecting absence of the at leastone safe-operation sensor; automatically altering at least one normaloperating mode of the movable barrier operator whenever the at least onesafe-operation sensor is not detected.
 23. The method of claim 22 andfurther comprising, during the at least one normal mode of operation andsubsequent to storing the at least one indicia, automatically detectingrenewed availability of at least one safe-operation sensor.
 24. Themethod of claim 23 and further comprising, during the at least onenormal mode of operation and subsequent to storing the at least oneindicia, and subsequent to automatically detecting renewed availabilityof at least one safe-operation sensor, again operating in an ordinaryfashion to selectively move the movable barrier as a function, at leastin part, of the at least one safe-operation sensor.
 25. The method ofclaim 24 wherein the at least one normal mode of operation and prior todetecting at least one safe-operation sensor comprises at least one ofan opening mode of operation and a closing mode of operation.
 26. Themethod of claim 24 wherein automatically altering at least one normaloperating mode of the movable barrier operator includes altering atleast one of a closing mode of operation and an opening mode ofoperation of the movable barrier.
 27. The method of claim 26 wherein:altering a closing mode of operation of the movable barrier includespreventing a movable barrier from fully closing during a closing mode ofoperation; and altering an opening mode of operation of the movablebarrier includes preventing a movable barrier from fully opening duringan opening mode of operation.
 28. The method of claim 26 wherein:altering a closing mode of operation of the movable barrier includes atleast stopping movement of the movable barrier towards a closedposition; altering an opening mode of operation of the movable barrierincludes at least stopping movement of the movable barrier towards anopened position.
 29. The method of claim 28 wherein: altering a closingmode of operation of the movable barrier further includes reversingmovement of the movable barrier away from the closed position; alteringan opening mode of operation of the movable barrier further includesreversing movement of the movable barrier away from the openingposition.
 30. The method of claim 22 wherein automatically detecting atleast one safe-operation sensor includes automatically detecting anobstacle detection sensor.
 31. The method of claim 30 whereinautomatically detecting an obstacle detection sensor includesautomatically detecting at least one of a light-based obstacle detectionsensor, a sound-based obstacle detection sensor, a radio frequency-basedobstacle detection sensor, and a contact-based obstacle detectionsensor.
 32. The method of claim 22 and further comprising, subsequent tostoring the at least one indicia, an indicia-clearing mode during whichthe at least one indicia is removed from storage.
 33. The method ofclaim 32 and further comprising, subsequent to removing the at least oneindicia from storage, engaging in the at least one normal mode ofoperation as before when the at least one safe-operation sensor wasdetected.
 34. A method for use with a movable barrier operator,comprising: providing a first mode of normal operation for use without asafe-operation sensor comprising: selectively moving a movable barrierwithout use of a safe-operation sensor; automatically monitoring foravailability of a safe-operation sensor; automatically storing anindicator corresponding to an available safe-operation sensor; providinga second mode of normal operation for use with a safe-operation sensorcomprising: selectively moving the movable barrier with use of thesafe-operation sensor; automatically monitoring for availability of thesafe-operation sensor; automatically modifying the second mode of normaloperation when the safe-operation sensor is not detected.